Installing Strain Gain Transducers

INTRODUCTION

Installing a HELM load monitor or a load measurement system can be divided into four basic
segments:

1.) Selecting the sensor mounting locations.

2.) Installing the STRAlN GAIN load sensors and instrument.
3.) Inter-connecting the sensors to the instrument.
4.) Calibrating the press and making final instrument-adjustments.

Generally, HELM is requested to supervise the customer’s personnel for steps 1,2 and 3. We
almost always do the calibration. Special equipment and training is required for the calibration and
adjustment (step #4). This article is provided for those customers who are confident they can
perform the first three steps without our direct supervision. Part of this article explains the role of
the customer in the final calibration procedure.

SELECTING THE SENSOR LOCATION

Basic Principles of Measuring Press Loads

As a press forms a product, the press structure is strained. The tie-rods and columns of a
straightside press will stretch. The frame of a Gap-Frame or O.B.I. press will open up. The
amount of strain on the press is directly related to the work that is done... the ”load” on the press
structure.

Strain-sensing ”transducers” are mounted to strategic high-stress areas of the press frame. Sig-
nals from these sensors are routed to the instrument for processing. The instrument will display
the strain in ”tons-of-force” or in ”percentage-of press capacity”. Adjustable alarm levels are
provided in the instrument so the customer may select what he considers an off-tolerance or
overload condition.

Some areas of the press structure are highly stressed and provide excellent representative load-
signals. Other areas are lightly stressed and only poor and non-linear signals are available. Only a
few years ago, picking a good sensor location was only done by specially trained people. HELM
development has produced highly sophisticated sensitive instruments with extreme stability.
Sensor locations that were useless only a few years ago are now perfectly satisfactory for use with
our systems.

With our modern systems, and using reasonable care, it is now practical for a customer to pick
sensor locations on common presses. True, such machines as under-drives, multi-column
presses and special ”exotic” presses still need professional study. In special cases, simply con-
tact us and we will tell you the best location for your sensor.

1
 Installing Strain Gain Transducers

Selecting a Sensor Location... ”C” Frame Presses

A Gap-Frame or O.B.I. press ”opens” up when it does work. This puts the throat area in tension
and the rear of the web of the press in compression. Figures 1 & 9 show typical sensor- mounting
locations on an O.B.I. press. Locations would be similar for a typical Gap-Frame press. Pick a
location where the sensor will not be damaged by stock movement through the press, passing
vehicles, changing tooling, etc.

We have found the load signals from the throat of the press to be the most dependable. The only
time the rear of the press would be most desirable is when the throat area is obstructed with
tooling. If the press has reinforcing tie-rods, the rear of the press cannot be used.

NO GOOD

GOOD GOOD GOOD GOOD

- Fig. 1 -

The best location wouId be in the throat area marked in gray. The manufacturer has generally
”beefed up” this area because of the high stresses. Avoid putting the sensor near a corner or a
change-in-section. That area could provide a non-linear signal. If at all possibIe, stay in the center
of the ”O.K.” zone (of figure 1). This area provides a good, dependable ”TENSION” sig- nal.

The second best location would be as near as possible to the rear edge of the upright web. Some
types of presses have relatively thin webs. This causes them to bow in or out when the press is
loaded. The load signal will be distorted if such bowing is significant or excessive. Sensors at the
rear of the press will provide a usable ”COMPRESSION” signal.

The area marked ”no good” must be avoided. Also, avoid putting sensors near the gibs. Signals
near the gib area may vary from somewhat non-linear to extremely weak. Try to mount the
sensors at the same height on the press. For example; if you put the left sensor at the left edge of
the throat, 4 inches above the bed, mount the right sensor on the right edge of the throat, 4 inches
above the bed.

2
 Installing Strain Gain Transducers

O.B.I. presses with tie-rods must have the sensors mounted in the throat area. The signal at the
rear of the press will generaIly be erratic. The tie-rods must be tight.

Selecting a Sensor Location . Straightside Presses

The tie-rods of a straightside press will stretch when the press is loaded. This obviously allows the
compressed columns to stretch. Although the tie-rods themselves provide excellent load signals,
mounting sensors to the tie rods is not normally practical. The columns provide excel- lent load
signals if care is used in picking a high-stress location.

Figure 2 shows some typical locations of tie-rods within columns. The arrowheads show the first
choice and second choice sensor-mounting location of each type of column. Note that the first
choice is always the wall closest to the centerline of the tie-rod. Areas of the column away from
the centerline of the tie-rod are perhaps distorting as the press is loaded. This can cause non-
linear or weak signals.

Columns d, e, i and j of figure 2, have false waIls. Any walls surrounding the gray areas will
generally be useless for measurement purposes. The signals will be either very weak or non-
existent. The false walls will, of course, be stressed. However, don’t trust these walls for load
measurement.

The columns a, b, c, f, g and h have some walls without arrows. There will be load signals there
but they could be unpredictable. If you must use one of these walls, consult HELM first.

1 1 1 1 1

2 2 1 2 2 2 1
1 1
a b c d e
1
FALSE WALLS
1 1

1 2 2 2

1 2 1 1

f g h i 2 j 2

1
Tie-rods in columns . . . . Looking down inside columns
- Fig. 2 -

3
 Installing Strain Gain Transducers

Figure 3 shows the rear and end views of a basic straightside press with the tie-rods centered in
the column and no false waIls. Note that we have marked the ”good” locations with an ellipse. We
don’t mean you may mount sensors anywhere inside the ellipse. You must stay on the centerline
of the tie rod. However, the widest part of the ellipse represents the best mounting location. The
narrower parts of the ellipse represent a poorer but still satisfactory location.

CENTERLINE
CL OF CL CL CL
TIE-ROD

REAR END

GOOD
GOOD LOCATION GOOD

- Fig. 3 -

In some presses there are openings in the columns at the areas we show as ”good” locations. In
this case, mount on either side of the opening. Do not mount directly above or below the opening
because the signal level there is not predictable. If you have doubts, call HELM.

Try to keep all the sensors at the same approximate height above the base of the column. Note
that in figure 3 we show the vertical midpoint of the column as being good but the bottom of the
column as being less desirable.

We say to position the sensors at the same height on the coIumn. All this appears to be con-
tradictory. However, compromise is perfectly acceptable. The result of the compromise will be a
loss in signal. But, you should still have plenty of signal for accurate use of our instrument.

4
 Installing Strain Gain Transducers

Figure 5 shows typical mounting locations on a solid frame press. Be careful with this type of
press. Load distribution is sometimes unusual. The most dependable mounting location is shown.
The major problem will be locating the sensors in that area and still keeping them safe from
damage. What is shown as ”bad” areas are generally unpredictable areas. If these ”bad” areas
must be used either contact HELM or experiment.

TIE-ROD
CL

FRONT
CROWN

BAD BAD
AREA AREA

RAM

GOOD
GOOD AREA
AREA FRONT REAR

BED

BASE

Solid-frame press . . . End view

- Fig. 4 - - Fig. 5 -

Figure 6 shows some of the various ways people refer to the press columns. Some even call them
northwest, south, east, etc. Some of our instruments refer to columns as 1, 2, 3 and 4. You will
probably find ”left front”, ”right front”, etc. to be the least confusing.

A load monitor instrument has 2 or 4 ”channels”. A 2-channel instrument generally measures the
left and right side of the press. Channels 1 and 2 of a 4-channel instrument measures the left side
of the press. Channels 3 and 4 measure the right side. Some instruments are labeled LEFT and
RIGHT. Some instruments are labeled LF, RF, LR, and RR.

5
 Installing Strain Gain Transducers

Channel 2 (or 3 & 4)

B D
CL
LEFT REAR RIGHT REAR

CL
2 4
TIE ROD (TYP)
DIE AREA

1 3
CL

LEFT FRONT RIGHT FRONT

A C
Channel 1 (or 1 & 2)

- Fig. 6 -

MOUNTING THE STRAIN GAIN LOAD-SENSING TRANSDUCERS

A HELM load monitoring system is composed of: a portable or permanent-installation instru- ment
with either one, two or four ”channels”; one STRAIN GAIN load sensing transducer for each
instrument ”channel”; mounting and protective hardware for each STRAIN GAIN sensor. The
sensors and hardware are available as installation kits. Each kit includes enough transducers,
mounting hardware, and protective hardware for all the ”channels” of the system. This pamphlet
explains what the various components are called, how they are used, and which kits are used for
various instrument installations.

Instruments are grouped in two categories, portable instruments (such as the PORTA-PEAK) and
permanent-installation systems (such as the LOADGARD series of instruments). PORTA-PEAK
instruments are produced as two-channel or four-channel models. LOADGARD instruments are
produced as one-channel, two-channel, or four- channel models.

The main difference between a PORTA-PEAK installation kit and one for a LOADGARD is the
covers of the protective shells. Sensor wires are connected directly to terminals inside a
LOADGARD instrument. Sensor wires are connected to a PORTA-PEAK by means of a cable and
a connector. Protective shells in a LOADGARD kit are provided with blank covers. Special flip-lid
covers with a cable connector are provided for PORTA-PEAK installations.

If a PORTA-PEAK installation is being done it will be necessary to solder the sensor wires to the
connector. Connector wiring is covered in figure 12.

6
 Installing Strain Gain Transducers

TWO TYPES OF MOUNTING KITS... WELD OR DRILL

There are two methods of mounting the load sensors to a machine... Direct mounting by means of
holes drilled into the machine... Indirect mounting by using pre-drilled steel blocks (weld pads)
welded to the machine. Therefore, kits will be referred to as either ”Weld-Pad” mounting or
”Drilled-Hole” mounting.

Transducers Bolted Transducers Bolted to

Directly to the Press Pre-Drilled & Tapped Weld Pads

The Installation Kits

There are a total of ten transducer/installation kits. Four kits are for the PORTA-PEAK instru-
ments. Six kits are for permanent-installation systems such as LOADGARD. Here is how they are
divided:

FOR PORTA-PEAK INSTRUMENTS:

Two-channel PORTA-PEAK, drilled-hole mounting ................................................. PK-2D
Two-channel PORTA-PEAK, weld-pad mounting .................................................... PK-2W
Four-channel PORTA-PEAK, drilled-hole mounting ................................................ PK-4D
Four-channel PORTA-PEAK, weld-pad mounting ................................................... PK-4W

FOR LOADGARD-TYPE SYSTEMS:

One-channel system, drilled-hole mounting ............................................................. L1-DB
One-channel system, weld-pad mounting ................................................................ L1-WB
Two-channel system, drilled-hole mounting ............................................................. L2-DB
Two-channel system, weld-pad mounting ................................................................ L2-WB
Four-channel system, drilled-hole mounting ............................................................ L4-BD
Four-channel system, weld-pad mounting ............................................................... L4-WB

7
 Installing Strain Gain Transducers

Additional Installation Kits

For larger straightside presses and where longer leads are required, the following kits may be
ordered. Note, these kits are designed to be used with two, four, or eight channel permanently
installed units, (LOADGARD/TREND LOADGARD) and come standard with weld hardware.
Please specify drill hardware, if needed.

L4-WTS-350 kit includes: (4) sensors, (4) covers with terminal strips, (4) T-21 protection shells.
L4-WB and (1) 350 ft. roll of strain gain cable.

Notes:

A.) Longer or shorter rolls of cable are available ie: L4-WTS-250, 350, 450, 550, etc.

B.) The standard L4-DB or WB kits come with sensors that have 35 ft. lead or 140 ft. of cable L4-
WB total.

8
 Installing Strain Gain Transducers

Items included in each Transducer/Installation kit:

FIXTURES

SENSOR SHELL COVER COVER DRILL WELD PADS

KIT HT-400-35 T-21 WS WRS DF-400 WF-400 WP-400

PK-2D 2 2 1 1 1
PK-2W 2 2 1 1 1 2 sets
PK 4D 4 4 2 2 1
PK-4W 4 4 2 2 1 4 sets
L1-DB 1 1 1 1
L I –WB 1 1 1 1 1 set
L2-DB 2 2 1
L 2 –WB 2 2 2 1 2 sets
L4-DB 4 4 4 1
L 4 –WB 4 4 4 1 4 sets

Each installation kit Includes an appropriate number

of model HT-400-35 STRAIN GAIN load-sensing
transducers. For example, there is one STRAIN
GAIN sensor in the L1-DB kit, two sensors in the
PK-2D kit, four sensors in the L4-WB kit and so on.

Each sensor is provided with two anti-torque

washers, four mounting bolts, and a hex wrench to
fit the bolts. Any STRAIN GAIN sensor ordered
separately will also include the washers, boIts and
wrench.

HT-400 Transducer

Each transducer/installation kit Includes either one welding

fixture or one drilling fixture. The welding fixture is designated
“WF-400”. The drilled- hole fixture (drill-guide) is designated
”DF-400”. This means either ”Weld Fixture for HT-400 series
transducers” or ”Drill Fixture for HT-400 series transducers”.

DF-400 Drill Fixture

WF-400 Weld Fixture

9
 Installing Strain Gain Transducers

If a welded-installation kit is selected there will be one set (2 pads) of

WP- 400 weld pads and four mounting bolts included for each
STRAIN GAIN sensor in the kit. The bolts are for temporarily mounting
the weld pads to the weld fixture. They will not be used for mounting
the sensor. WP-400 weld pad sets, with bolts, may be ordered
separately.

Each installation kit includes an appropriate number of protective shells to enclose the load
sensor. The covers of the shells are either blank or contain a connector, depending on whether
the installation is for a permanent LOADGARD type system or for PORTA-PEAK use.

FOR USE WITH LOADGARD INSTRUMENTS FOR USE WITH PORTA-PEAK INSTRUMENTS

T-21 SHELL T-21 SHELL

WS COVER
WRS COVER

10
 Installing Strain Gain Transducers

Basic Mounting Instructions for Helm Strain Gain Sensors

1.) Align sensor with the line of force of machine component, as shown.
2.) Rotate sensor 180° to change cable exit orientation (optional).
3.) Mount sensor with nameplate facing out (away from mounting surface).
4.) See the following pages of this manual for more installation details.

Typical Strain Gain Sensor Orientation

LINE OF FORCE LINE OF FORCE

RIGHT-SIDE ROTATED POSITION

CABLE EXIT (180 DEGREES)
MAUMEE, OHIO USA
CO., INC.
HELM INSTRUMENT
S/N 24655
HT400 STRAIN GAIN
STRAIN GAIN HT400
S/N 24655
HELM INSTRUMENT
CO., INC.
MAUMEE, OHIO USA

LEFT-SIDE
STANDARD POSITION CABLE EXIT

LINE OF FORCE LINE OF FORCE

Drilled-Hole Mounting

11
 Installing Strain Gain Transducers

It is extremely important that the mounting surface of the machine be smooth, clean and very flat.
There must be no burrs around the drilled holes. If the surface is not flat the sensor will be twisted
when it is tightened. This will cause a shift in no-load zero balance. If this happens, the sensor will
generally have a reduced working range or perhaps even be bent and damaged. It is also
necessary that the sensor be aligned to the direction of force. In almost every case, this means
the sensor be mounted vertically as shown in figure 9. Also, the sensor should always be mounted
with the nameplate facing outward (away from the mounting surface). In the standard position,
the sensor cable exits the right side of the sensor body. If a left-side cable exit is desired, for
clearance or a uniform interconnect configuration for multiple sensors, then the sensor can be
rotated 180° from top to bottom. This position puts the cable on the left-hand side of the body and
the nameplate will appear upside-down. The sensor will function normally in this position (see
page 11 for illustration). We do not recommend mounting the sensor with the nameplate facing in
toward the mounting surface, as a decrease in output signal will result.

1 2
Grind mounting surface to have bare
metal, smooth and flat. Hold sensor or drill
guide to surface. It should not rock Scribe
a vertical line to position the sensor
properly.
Using center hole in drill guide, bolt
guide to press. Drill remaining holes
about ¾ inch deep with #3 drill. Tap
holes ¼-28. Remove guide, de-burr
holes and clean thoroughly..

3 4
Hold drill guide to vertical line. Using “anti-torque washers” as shown, bolt
Drill center hole about ¾ inch deep sensor to press structure. Tighten 4 bolts
with #3 drill. Tap hole ¼-28. to about 175 in. lbs.

Note the sensor nameplate

Should always be facing
out (away from surface).

12
 Installing Strain Gain Transducers

NOTE: If you have protective shells (T-21) for enclosing the sensor, see figure 10 and the ac-
companying text for special procedures.

Weld-Pad Mounting

There are some simpIe cautions to observe when using the weld-pad method of sensor mount-
ing.

§ You must assure the fixture and pads are properly aligned with the direction of force. This will
almost always be vertically as shown in figure 8 and figure 9.

§ The pads must be held firmly against the machine surface and each pad must be tack-welded
before finish-weld is done. If only one pad is tack-welded, the other pad will generally lift away
from the surface. Unless both pads are firmly welded flat against the machine sur- face, the
sensors may not provide proper load-sensing

§ The finished weld shouId be tested by prying firmly with a screwdriver/between the fixture and
machine surface. A poor weld will obviously let go.

§ The weId-pads must remain firmly attached to the fixture until all welding is complete and the
fixture is cool enough to be held in a bare hand.

The weld-pads are made of 1018 mild steel. For welding to a cast iron machine we suggest N1-
ROD-55 (INTERNATIONAL NICKEL CO.). Although a mounting hole is provided in the center of
the fixture, most welders prefer to mereIy hold the fixture/pads firmly to the press with a gloved
hand. In almost every case this works well.

NOTE: If you have protective shells (T-21) for enclosing the sensor, see figure 10 and the ac-
companying text for special procedures.

13
 Installing Strain Gain Transducers

Assemble weld pads to Without removing

fixture as shown. Grind fixture, weld outer sides
and sand paint from of each pad. It is not
mounting surfaces. necessary to weld inside FORCE

Surface should be clean edge of pad. Remove

and reasonably flat. fixture.

1 3
TACK 2 4

Align weld pads with Using “anti-torque washers”

direction of force (see Fig. as shown, bolt sensor to
9). Hold pads firmly press structure. Torque 4
against mounting surface. FORCE
bolts to about 175 in. lbs.
Tack weld both pads to
surface before finish weld-
ing is started.

TACK

Figure 9 shows various presses with tension and compression symbols at recommended sen-
sor-mounting locations. It is important to align the sensor with the direction of force. In the ex-
amples shown, this would mean with the two upper sensor mounting holes toward the top of the
press and the two lower holes toward the bottom. This to most people would seem obvious.
However, we have seen many cases where the instalIer mounted the sensors horizontally or on
an angle.

STRAIGHTSIDE GAP - FRAME O.B.I. ALIGN

SENSOR

TENSION
HT400
STRAIN GAIN
S/N 24655
HELM INSTRUMENT
CO., INC.
MAUMEE, OHIO USA

COMPRESSION

- Fig 9 -

14
 Installing Strain Gain Transducers

Mounting the Protective Shells (T-21) TACK WELD

CL
The T-21 protective shells may be mounted to the press either with
the hardware provided or by tack welding them to the press. Refer
to figure 10. Make certain the sensor is centered inside the shell. If
it isn’t, you couId have trouble getting at the sensor-mounting bolts.
WELD PADS
To protect the sensor, we suggest you do not have it on the press
while you are mounting the shell. Make certain the sen- sor-
mounting location is thoroughly cleaned after drilling and tapping
the shell-mounting holes. If you are mounting the shell by welding it STRAIN GAIN
to the press, tack-weld only two corners (either top-right/bottom left
or top-left/bottom right). It is not necessary to fully weld the top and CL HT400
STRAIN GAIN
S/N 24655
bottom of the shell (you may want to remove the shell someday). HELM INSTRUMENT
CO., INC.
MAUMEE, OHIO USA

Use care when pulling the sensor cables through the conduit. The T-21
wires inside the cable are thin. Under normal circumstances they SHELL
will not be damaged during pulling. However, unnecessary strain
due to careless pulling may stretch or break one or more wires.
This is a rare occurrence but we mention the possibility so you may
guard against it.

TACK WELD

- Fig. 10 -
CABLE TO INSTRUMENT

Connecting the Sensor Cables to the Instrument

Figure 11 shows some typical methods for cable routing. For best electrical shielding we sug- gest
running the cables through metal conduit. However, some customers have used flexible tubing.
Under no circumstances should sensor cables be put into conduit containing any other type of
wires or cables... you cannot imagine the problems you will have if you disregard this rule.

The four LOADGARD installations (figure 11 A,B,C,D) should be used with ”T-21” protective
shells with ”WS” blank covers. The load sensors will be ”hard wired” directly to terminal strips
within the instrument. The two PORTA-PEAK installation (figures 11 E,F) will aIso use ”T-21”
protective shells. Installation E uses one ”WS” blank cover and one ”WRS” cover with a con-
nector. InstaIlation F uses two ”WS” blank covers plus two ”WRS” covers with a connector in each
cover. The connectors in the ”WRS” covers must be wired as per the color code shown in figure
12.

15
 Installing Strain Gain Transducers

2 CHANNEL LOADGARD / 2 SENSORS

L R

L R
A
2 CHANNEL LOADGARD / 4 SENSORS 4 CHANNEL LOADGARD / 4 SENSORS

* L2 R2 **

* L1 R1 **

* Wire L1 & L 2 L/F R/F

in parallel 1 3

** Wire R1 & R2 2 4
in parallel L/R R/R
L R
B C
4 CHANNEL PORTA-PEAK / 2 SENSORS 4 CHANNEL PORTA-PEAK / 4 SENSORS

2 4

L R

1 3

D E
TYPICAL SENSORS CONNECTED TO VARIOUS INSTRUMENTS
- Fig. 11 -

16
 Installing Strain Gain Transducers

Please note that the wiring diagram shows the rear of the connector, #1 sensor is on the right.
Soldering small wires into a connector requires care and skill. Make certain there are no shorts or
solder bridging between the terminals. It is good practice to place short pieces of plastic tubing
(spaghetti) over the terminals. The wiring diagram shows the connections for sensors with a
TENSION signal (see figure 9). For a COMPRESSION signal you should put both green wires to
terminaI B and both black wires to terminal A. This will reverse the excitation to the strain gages
inside the sensor. DO NOT change the white and red wires PLUS the red and black wires. To do
so would put you right back where you started.

It is perfectly acceptable to coil up some excess sensor cable within the protective shell. Just don’t
try to stuff the shell full. It is also perfectly acceptable to cut off unneeded excess cable. This will
not affect the accuracy of the load measurements. It is not acceptable to splice the cable without
instructions from HELM.

Proper terminations to LOADGARD type instruments will be covered fully in each instruction
manual.

7 PIN FEMALE AMPHENOL CONNECTOR

T-21 ENCLOSURE

CONNECTOR CODE
PIN A - (+GAGE)
F A PIN B - (-GAGE)
E G B
PIN C - (+SIGNAL)
PIN D - (-SIGNAL)
D C PIN E - (OPEN)
PIN F - (OPEN)
PIN G - (SHIELD)

BACK VIEW WRS COVER

7 PIN FEMALE AMPHENOL

- Fig. 12 - CONNECTOR

CALIBRATING THE PRESS AND INSTRUMENT

Complete details of press caIibration is beyond the scope of this article. Each instrument manual
contains details for making the instrument adjustments. What we present here is a basic descrip-
tion of the calibration procedure and how the customer is involved in that calibration.

17
 Installing Strain Gain Transducers

To calibrate a system requires the use of specialized equipment. If you have such equipment, you
have been trained how to use it. Therefore, you may ignore this section of the article.

Basic Principles of Calibration

Assume you drilled two small holes in the upright of a press, exactly 2 inches apart, one directly
above the other. As the press operates to form a part, the columns stretch and the holes move
apart a few millionths of an inch. Assume 100 tons of load on the press caused the holes to move
apart 100 millionths of an inch. In this exampIe 1 millionth of an inch stretch would equal 1 ton of
load.

A two-inch long STRAIN GAlN load sensor wired to an instrument channel provides a very prac-
tical ”electronic micrometer”. As the column stretches, the sensor puts out a signal directly re-
lated to the amount of stretch. The instrument then translates the amount of stretch into tonnage.
However, we must force the press to do a specific amount of work so we can adjust the
instrument to precisely display that exact amount of work. In other words, we must adjust the
signal ”gain” of the instrument.

Once we have made the precise “gain” adjustment, the load is removed from the press. An
electronic simulated-load is then applied to the instrument. The instrument will then display a
”CAL” (calibration) number. The CAL number is recorded for use whenever the system is to be
tested.

Once a press calibration is performed, you may change instruments or sensors and never need to
re-calibrate unless you make a major physical change in the press structure.

Calibration Procedure

Special ”load cells” are used to measure a specific amount of impact made upon them by the
press ram. (Think of these cells as high-capacity scales.) If the ram hits the cells with 100 tons of
force, the press structure will stretch by a specific amount. That amount of stretch is detected by
the STRAIN GAIN sensor. The instrument would then be adjusted to display 100 tons.

Obviously we use 100 tons only for illustration purposes. Generally the press is forced to do work
equal to its maximum rated capacity. HELM is capable of providing full-capacity routine calibration
on presses up to 8000 tons. (Under special conditions, presses with greater capacities may be
calibrated to maximum limits.)

See figure 13 for typical instrument connections during caIibrations. As the ram impacts cells 1 &
2, for the force of the impact (load) is displayed on the PORTA- PEAK. The STRAIN GAIN
sensors aIso detect the force of the impact and put a signal into the LOADGARD instrument. The
LOADGARD is then adjusted to match the PORTA-PEAK display.

18
 Installing Strain Gain Transducers

CL CL Centerline
of connections

Ram shown
at B.D.C.

Load Monitor
connected to
Bolt-on
bolt-on sensors
strain gage
sensors

Shims

Stack-up

Calibration load cells 125 125 1 1

500
125 125

Portable load monitor connected

to calibration load cells
- Fig. 13 -

1/8” tempered masonite shims, hard on both sides, are provided by HELM when we do the
calibration. The stack-up is steel material and furnished by the customer. Note that the tooling has
been removed from the press bed and slide. In rare cases, calibration can be done with tooling in
the press, but don’t count on it.

Calculating Stack-Up Height and Material

Having the proper stack-up material prepared in or near the press will greatly speed up calibration
and decrease downtime. The following guidelines will help you determine the stack-up. Refer to
figures 13 and 14.

§ Use steel only. Solid steel die-risers, solid steel plates, or solid steel ”round stock” is fine.
Don’t use I-beams, channels, etc. No aluminum, brass, etc.
§ There must be one stack-up for each connection (pitman). One cell per pitman is generally
used.
§ The top and bottom stack-up surfaces should be reasonably parallel. Machining the stack-up
to improve parallelism is not generally necessary. Reasonable non-parallelism will be leveled
out by shim material.

For presses over 400 tons, load cells with a 1000 ton capacity will be used. They must set on a
stack-up at least 10” wide and 10” front-to-back... 12” x 12” or larger would be better.

19
 Installing Strain Gain Transducers

Example “Stack Up”

Connection

Ram

B=4 ¼ inches

Loadcell
A
C=A-B
Stack-Up

Bolster
Stack up = Ram to Bolster Height - Load Cell Height
L.C. Cable
to Porta Peak
- Fig. 14 -

§ If height ”C” (figure 14) exceeds about 4 ft. on presses over 400 tons, each stack up should
be about 12” x 48”.
§ On presses with a maximum rated capacity under 400 tons, smaller cells will be used. They
must set on a stack-up at least 3 1/2” wide and 3 1/2” front-to-back. Preferably, the stack up
should be a bout 6” x 6” or more.
§ If height ”C” (figure 14) exceeds about 18”, the stack-up must be at least 6” x 6”.
§ There must be one stack-up for each load cell or one stack-up long enough to position each
cell directly under each pitman.

To calculate the height of each stack-up, refer to figure 14 and proceed as foIlows:
§ Put the ram (slide) adjustment control to the center of its range.
§ Run the ram (slide) to exactly bottom center (180 degrees).
§ Measure the distance from the top of the bolster to the bottom surface of the ram (slide). This
will be measurement ”A”.
§ The load cell/shim height ”B” is 4 1/4 inches for a 100 ton cell, 5 inches for a 250 ton ceII, and
4 inches for a 1000 ton cell.
§ Subtract the proper load cell height from measurement ”A”. This will give ”C” the height of the
stack-up.

Example... Height ”A” is measured as 17 3/4. Load ceII/soft-shim height ”B” of 4 1/4”. 17 3/4”
minus 4 1/4” equals a required total stack-up of 13 1/2”. You could use a 12” high stack-up if you
have enough slide controI. Keep in mind that slide control during calibration would be as important
as if you were running parts in a die. Make certain that you choose a stack-up height that will allow
both up and down slide control during calibration.

20